Led lighting system with reflective board

ABSTRACT

A light emitting apparatus ( 8 ) includes one or more light emitting chips ( 10 ) that are disposed on a printed circuit board ( 12 ) and emit light predominantly in a wavelength range between about 400 nanometers and about 470 nanometers. The printed circuit board includes: (i) an electrically insulating board ( 14 ); (ii) electrically conductive printed circuitry ( 20 ); and (iii) an electrically insulating solder mask ( 22 ) having vias ( 24 ) through which the one or more light emitting chips electrically contact the printed circuitry. The solder mask ( 22 ) has a reflectance of greater than 60% at least between about 400 nanometers and about 470 nanometers.

BACKGROUND

The present invention relates to the lighting arts. It especiallyrelates to high intensity light emitting diode packages, components,apparatuses, and so forth, and will be described with particularreference thereto. However, the invention will also find application inconjunction with other solid state light emitters such as verticalcavity surface emitting lasers.

High brightness light emitting packages typically employ a plurality oflight emitting diode chips, surface emitting laser chips, organic lightemitter chips, or the like. To mechanically support the chips and toelectrically interconnect the chips, in some light emitting packages thelight emitting chips are disposed on a printed circuit board. Theprinted circuit board can also support and electrically incorporatediscrete electronic components, application-specific integrated circuits(ASICs), programmable microprocessors, or the like, for providing inputpower conditioning, light output control, electrostatic dischargeprotection, or other functions.

Disadvantageously, the printed circuit board can contribute to opticallosses by partially absorbing light that impinges upon the printedcircuit board. Printed circuit boards typically include a topmost epoxysolder mask layer having lithographically defined openings through whichthe light emitting chips or other electronic components electricallycontact bonding pads of the printed circuitry. In conventional printedcircuit boards for electronic applications, the solder mask layer is notoptimized for its optical properties, and is thus not very reflective.

For high brightness light emitting packages, printed circuit boardshaving a commercially available white solder mask are sometimes used.These white solder masks contain white talc or another white materialthat reflects visible light. White solder masks provide a substantialimprovement in reflectance of visible light over conventional blue orgreen solder masks.

However, white solder masks have certain disadvantages for some highbrightness light emitting packages. First, while the white solder maskappears to be highly reflective, the inventors have measured thereflectance of such boards and have found that the reflectance is onlyabout 80% or less in the visible spectral region. If 50% of the visiblelight produced by the light emitting package impinges on the printedcircuit board, this reflectance corresponds to optical losses of around10% or higher due to absorption in the printed circuit board.

Moreover, the reflectance of the white solder masks decreases in theblue, violet, and ultraviolet spectral regions. The inventors have foundthe white solder board reflectance decreases below 60% for wavelengthsless than about 410 nm. In certain light emitting packages, wide-bandgaplight emitting chips emitting blue, violet, or ultraviolet lightemission are coupled with a phosphor that converts the light emissioninto white or another selected visible light. In such packages, asubstantial amount of blue, violet, or ultraviolet light typicallyreflects from the phosphor toward the printed circuit board. Therelatively low reflectance of white solder masks for blue, violet, orultraviolet wavelength light degrades the light output efficiency ofthese packages.

An approach for achieving high reflectances in the blue, violet, orultraviolet would be to use a metallic reflector. However, incorporatinga metallic reflector, which is generally electrically conductive, into asolder mask is problematic since the solder mask is in contact with orin close proximity to the printed circuitry and electronic componentleads.

The present invention contemplates improved apparatuses and methods thatovercomes the above-mentioned limitations and others.

BRIEF SUMMARY

According to one aspect, a light emitting apparatus is disclosed. One ormore light emitting chips are disposed on a printed circuit board andemit light predominantly in a wavelength range between about 400nanometers and about 470 nanometers. The printed, circuit boardincludes: (i) an electrically insulating board; (ii) electricallyconductive printed circuitry; and (iii) an electrically insulatingsolder mask having vias through which the one or more light emittingchips electrically contact the printed circuitry. The solder mask has areflectance of greater than 60% at least between about 400 nanometersand about 470 nanometers. Optionally, the electrically insulating boardand the electrically conductive printed circuitry of the printed circuitboard may include a plurality of electrically insulating layers and aplurality of layers of printed circuitry.

According to another aspect, a method is provided for fabricating alight emitting apparatus. An electrically insulating board is providedwith electrically conductive printed circuitry disposed thereon. Anelectrically insulating solder mask is disposed on the electricallyinsulating board. The solder mask has vias accessing the printedcircuitry, and has a reflectance of greater than 60% at least betweenabout 400 nanometers and about 470 nanometers. One or more lightemitting chips are disposed on the insulating solder mask. The one ormore light emitting chips electrically contact the printed circuitrythrough the vias in the solder mask, and emit light predominantly in awavelength range between about 400 nanometers and about 470 nanometers.

According to yet another aspect, a light emitting apparatus isdisclosed. One or more light emitting chips are disposed on a printedcircuit board and emit light predominantly in a wavelength range betweenabout 400 nanometers and about 470 nanometers. The printed circuit boardincludes: (i) an electrically insulating board; (ii) electricallyconductive printed circuitry; and (iii) an electrically insulatingsolder mask having vias through which the one or more light emittingchips electrically contact the printed circuitry. The solder mask has areflectance of greater than 60% at least between about 400 nanometersand about 470 nanometers. A phosphor is arranged to be irradiated by theone or more light emitting chips and emits light in a wavelength rangepredominantly above 470 nanometers responsive to the irradiating. Thephosphor and the printed circuit board are relatively arranged such thatat least some of the light emitted by the one or more light emittingchips predominantly in the wavelength range between about 400 nanometersand about 470 nanometers reflects from the phosphor onto the solder maskof the printed circuit board.

Numerous advantages and benefits of the present invention will becomeapparent to those of ordinary skill in the art upon reading andunderstanding the present specification.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may take form in various components and arrangements ofcomponents, and in various process operations and arrangements ofprocess operations. The drawings are only for purposes of illustratingpreferred embodiments and are not to be construed as limiting theinvention. In the drawings, layer thicknesses, coating thicknesses, andother dimensions are not drawn to scale.

FIG. 1 shows a perspective view of a light emitting package. In FIG. 1,one sidewall of the housing is removed to reveal internal components ofthe light emitting package.

FIG. 2 shows a perspective view of the printed circuit board andelectronic components of the package of FIG. 1.

FIG. 3 shows an exploded perspective view of the printed circuit boardand electronic components of the package of FIG. 1.

FIGS. 4 and 5 show perspective views of one of the light emitting chipsof the package of FIG. 1 from two different vantage points.

FIG. 6 shows a cross-section of a portion of a solder mask suitable foruse in the package of FIG. 1.

FIG. 7 shows a cross-section of a portion of another solder masksuitable for use in the package of FIG. 1.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

With reference to FIGS. 1–3, a light emitting package 8 includes aplurality of light emitting chips 10 disposed on a printed circuit board12. The illustrated printed circuit board 12 includes an electricallyinsulating board 14, which in the illustrated embodiment includes aconductive metal core 16 and an insulating layer 18 made of a fiberglassresin or another electrically insulating material. In some embodiments,the conductive metal core 16 is omitted: for example, the electricallyinsulating board may be a fiberglass resin board without a metal core.Electrically conductive printed circuitry 20 (shown in FIG. 3) isdisposed on the insulating layer 18 of the insulating board 14. A soldermask 22 is disposed on the insulating board 16 and includes openings orvias 24 (shown in FIG. 3) through which the light emitting chips 10electrically contact the printed circuitry 20. Optionally, one or moreadditional electronic components, such as the example electroniccomponent 26, are also disposed on the printed circuit board 12 andelectrically contact the printed circuitry 20 by the openings or vias24.

In the illustrated example, an electronic component 26 receiveselectrical power through contact pins 30 and rectifies, converts, orotherwise conditions the received electrical power to produce operatingpower delivered to the printed circuitry 20 to operate the lightemitting chips 10. Optionally, the electronic component 26 or anotherelectronic component can provide electrostatic discharge protection,selectable switching, or the like. The electronic component 26 can beembodied as an application-specific integrated circuit (ASIC), aprogrammed microcontroller or microprocessor, or the like. Alternativelyor additionally, electronic components can be embodied by discretecomponents such as resistors, inductors, capacitors, op-amps, digitallogic gates, or the like which are interconnected by the printedcircuitry to perform power conditioning, switching, a light dimmingfunction, or so forth.

In the illustrated embodiment, the electrically insulating board 14 ofthe printed circuit board 12 is a metal core board that includes theplanar conductive metal core 16, such as an aluminum plate, copper foil,or the like, along with the insulating layer 18. The insulating layer 18can be, for example, a fiberglass resin sheet or coating, whichelectrically isolates the printed circuitry 20 from the metal core 16.Optionally, the printed circuitry 20 electrically contacts the metalcore 16 at selected points through vias (not shown) formed in theinsulating layer 18, such that the metal core 16 acts as a ground platefor the printed circuitry 20. The metal core 16 also spreads and/ordissipates heat generated by the light emitting chips 10 and the one ormore electronic components 26.

The light emitting chips 10, the one or more electronic components 26,and the printed circuit board 12 are housed in a housing 36 (shown inFIG. 1). The housing 36 includes sidewalls 38, 40 and a bottom 42 onwhich the printed circuit board 12 is disposed. (One sidewall is omittedin FIG. 1 to reveal the internal components of the light emittingpackage 10; a second sidewall is disposed opposite the removed sidewalland is not visible in the perspective view of FIG. 1). The sidewalls 38,40 preferably have reflective interior surfaces 46. For example, thesidewalls 38, 40 and bottom 42 can define a rectangular metal box which,in addition to providing reflective interior surfaces 46, also providesa thermal heat sink for the example metal core printed circuit board 12.A top 48 of the housing 36 faces the light emitting chips 10 includes aphosphor plate 50.

In operation, the light emitting chips 10 emit blue, violet, orultraviolet light predominantly in a wavelength range between about 400nanometers and about 470 nanometers. The emitted blue, violet, orultraviolet light irradiates the phosphor plate 50. A phosphor disposedon or dispersed in the phosphor plate 50 emits fluorescence orphosphorescence predominantly in a wavelength range above 470 nanometersresponsive to the blue, violet, or ultraviolet irradiation. The phosphorplate 50 is light-transmissive for the fluorescence or phosphorescenceso that the light emitting package 8 outputs light due to thefluorescence or phosphorescence.

In some embodiments, the phosphor includes one or more constituents thatproduce a white fluorescence or phosphorescence. In other embodimentsthe phosphor includes one or more constituents that produce fluorescenceor phosphorescence of a selected color or blend of colors. Optionally,the phosphor plate 50 is also light-transmissive for the blue, violet,or ultraviolet irradiation produced by the light emitting chips 10, sothat the light output of the light emitting package 8 is a combinationof the fluorescence or phosphorescence output by the phosphor and directlight output by the light emitting chips 10. For example, in someembodiments the light emitting chips 10 produce blue emission light andthe phosphor produces yellow light, so that the blended direct andphosphor-generated light combine in the output of the light emittingpackage 8 to approximate white light. The reflective interior surfaces46 of the sidewalls 38, 40 reflect light produced by the light emittingchips 10 that impinges on the sidewalls 38, 40 toward the phosphor plate50 to improve light extraction efficiency.

In the illustrated embodiment, the sidewall 40 includes electricallyinsulated feedthrough openings 52 through which the contact pins 30 ofthe electronic component 26 pass to enable connection of an electricalpower source to the light emitting package 8. Other power inputconfigurations can also be used, such as a female power receptacle, ahard-wired electrical power cable, or the like. Optionally, a battery(not shown) is included in the light emitting package so that noexternal power supply is needed.

It will be appreciated that the housing 36 is only an example. Thehousing can have other shapes besides rectangular, can includephosphorized sidewalls in addition to or in place of the phosphorizedtop, or can include other modifications. In some embodiments, thehousing includes a phosphorized dome arranged over the light emittingchips. The light emitting package 8 can also include additional or othercomponents, such as a heat sink, heat radiating fins, a lens or otheroptical component or components optically coupled with the phosphorplate 50, lensing for focusing the light emitting chip emission onto aphosphorized window or region, or so forth.

With continuing reference to FIGS. 1–3 and with further reference toFIGS. 4 and 5, each light emitting chip 10 can be a light emittingdiode, a vertical cavity surface emitting laser (VCSEL), a monolithicarray of light emitting diodes or lasers, an organic light emittingchip, or the like. In the illustrated embodiment, each light emittingchip 10 includes a semiconductor chip 60 flip-chip bonded to a sub-mount62. The sub-mount 62 includes electrical vias electrically connectingthe semiconductor chip 60 with backside bonding pads 64. The illustratedlight emitting chip 10 is only an example; in other embodiments thelight emitting chip may be direct-bonded to the printed circuit board 12without a sub-mount, or may be bonded to a sub-mount but electricallycontacted to the printed circuit board using wire bonds, or may beflip-chip bonded to bonding pads of a sub-mount which sub-mount bondingpads are electrically connected with the printed circuit board 12 bywire bonds, or so forth.

In some embodiments, the light emitting chips are group III-nitridebased light emitting diodes or lasers emitting light predominantly in awavelength range between about 400 nanometers and about 470 nanometers.Other blue, violet, or ultraviolet light emitting chips can be employedwhich emit light predominantly in a wavelength range between about 400nanometers and about 470 nanometers. In some embodiments, the electricalconnections of the light emitting chips 10 to the printed circuit board12 are produced by soldering. The solder mask 22 keeps the solder in theareas of the vias 24. In other embodiments, thermosonic bonding,thermocompressive bonding, or another bonding technique is used.Regardless of whether soldering or another bonding technique employed,the solder mask 22 protects the printed circuitry 20 from abrasion orother physical damage.

To maximize light extraction efficiency, the solder mask 22 of theprinted circuit board 12 is constructed to have a reflectance of greaterthan 60% at least between about 400 nanometers and about 470 nanometers.In this way, the blue, violet, or ultraviolet light emitted by the lightemitting chips 10 which directly impinges upon the solder mask 22 (orwhich reflects off the sidewalls 38, 40 and/or the phosphor plate 50 andthen impinges upon the solder mask 22) is substantially reflected towardthe phosphor plate 50 to contribute to generation of phosphorescence orfluorescence. In some preferred embodiments, the solder mask 22 of theprinted circuit board 12 is constructed to have a reflectance of greaterthan about 85% at least between about 400 nanometers and about 470nanometers. In some preferred embodiments, the solder mask 22 of theprinted circuit board 12 is constructed to have a reflectance of greaterthan about 85% at least between about 400 nanometers and about 740nanometers, so that the solder mask 22 also reflects phosphorescence orfluorescence generated by the irradiated phosphor that is directedtoward the printed circuit board 12. In some preferred embodiments, thesolder mask 22 of the printed circuit board 12 is constructed to have areflectance of greater than about 85% at least between about 400nanometers and an upper wavelength substantially spanning the wavelengthrange of light emitted by the phosphor (for example, at least up to anupper wavelength of 650 nanometers for an example phosphor emittinglight predominantly in a wavelength range of 500–650 nanometers).

With reference to FIG. 6, in some embodiments, the electricallyinsulating solder mask 22 is formed of a film of photostabilizedelectrically insulating binder material 70, such as a photosensitiveepoxy, a photosensitive polyimide, or so forth, in which particles of areflective filler material 72 are dispersed. The particles of reflectivefiller material 72 can be, for example, a titanium oxide (such astitanium dioxide, TiO₂), an aluminum oxide (such as alumina, Al₂O₃), ahigh-refractive index glass, or so forth. The concentration of fillermaterial 72 in the binder material 70 as well as the mean particle size,average particle shape, and so forth are selected to provide adequatereflectance for the solder mask 22. An electrically conductive fillermaterial can be employed if its concentration is dilute enough to retainthe substantially electrically insulating characteristic of the soldermask 22.

In one example, in which the binder material is a negativephotosensitive epoxy, the solder mask 22 is constructed as follows. Theconstituents of the photosensitive epoxy are combined with the fillermaterial 72 to generate a liquid photosensitive epoxy source material,which is disposed on the electrically insulating board 14 as a film.Suitable deposition methods include spray coating, curtain coating, orso forth. Depending upon the type of epoxy, a soft cure may be performedto partially harden or solidify the photosensitive epoxy film. Softcuring is not employed with some types of epoxy, however. Theseprocesses are performed in a yellow-lighted photolithography room orother environment whose ambient illumination does not activate thephotosensitive epoxy.

The vias 24 of the solder mask 22 are then formed by optically exposingthe photosensitive epoxy film through a photo-mask that blocks lightexposure in the areas of the vias 24. The optically exposedphotosensitive epoxy film is developed using suitable chemicals whichremove only those areas of the photosensitive epoxy film which have notbeen exposed to light; thus, the areas of the vias 24 which were blockedfrom light exposure are removed to open up the vias 24. Those areaswhich were exposed to light are photostabilized and are not removed bythe developer chemical or chemicals. Depending upon the type ofphotosensitive epoxy, a hard cure may be performed to further solidifyor harden the photostabilized epoxy film.

In some embodiments, the concentration of filler material 72 is lowenough so that incorporation of the filler material 72 does notsignificantly alter the photosensitive characteristics of thephotosensitive binder material 70. In other embodiments, incorporationof the filler material 72 reduces the photosensitivity of thephotosensitive binder material 70. In these embodiments, the amount ofphotosensitizer in the photosensitive binder material 70 can beincreased to counteract the effect of the filler material 72, or thelight exposure and/or developing time can be increased to account forthe reduced photosensitivity. Typically, the solder mask 22 is betweenabout twelve microns and seventy-five microns thick. For a relativelythicker solder mask, the concentration of the filler material 72 cangenerally be reduced while retaining the desired reflectance. Fillermaterials such as TiO₂ or Al₂O₃ exhibit reflectances greater than about85% to 90% at least down to 400 nanometers, and more typically at leastdown to about 350 nanometers. Hence, for sufficiently highconcentrations of filler material 72, the reflectance of the solder mask22 can be increased to above 60% or above 85% (depending upon the fillerconcentration, reflectance characteristics of the particles, and soforth) in the wavelength range between about 400 nanometers and about470 nanometers.

With reference to FIG. 7, in some embodiments, the electricallyinsulating solder mask 22 is formed of a multiple-layer specularreflector sheet 80. Openings are cut into the sheet 80 to define thevias 24, for example using laser cutting, mechanical punching, or soforth, and the multiple-layer specular reflector sheet 80 is glued orotherwise secured to the electrically insulating board 14. The reflectorsheet 80 includes a stack of reflective dielectric layers includingalternating layers of dielectric material having different refractiveindices, different birefringence characteristics, or other dissimilaroptical characteristics. The thicknesses and optical characteristics ofthe layers are selected to provide a high stack reflectance in thewavelength range between about 400 nanometers and about 470 nanometers,and preferably in the wavelength range between about 400 nanometers andabout 740 nanometers.

In some embodiments, the multiple-layer specular reflector sheet 80 is acommercially available reflector sheet, such as a VM2000 reflector filmor a Vikuiti™ enhanced specular reflector film or a (available from 3M,St. Paul, Minn.). Solder masks formed of VM2000 or Vikuiti™ enhancedspecular reflector films have been measured by the inventors to havereflectances greater than 85% between 400 nanometers and 740 nanometers,with these high reflectances being observed for both front and backsides of the film. In contrast, a conventional white solder mask wasmeasured to have reflectances of about 80% in the visible, reflectancesof less than about 70% for wavelengths below about 430 nanometers, andreflectances of less than 60% for wavelengths below about 410nanometers.

The light emitting package 8 produces visible light through wavelengthconversion by the phosphor plate 50. In other contemplated embodiments,the light emitting package is a blue, violet, or ultraviolet lightsource that emits the direct light produced by the light emitting chipspredominantly in the wavelength range between about 400 nanometers andabout 470 nanometers. In these embodiments, optics, sidewalls, lenses,cover glasses, or so forth will generally reflect or otherwise redirectsome of the direct light predominantly in the wavelength range betweenabout 400 nanometers and about 470 nanometers toward the solder mask ofthe printed circuit board. Hence, the solder masks disclosed hereinwhich are highly reflective at least between about 400 nanometers andabout 470 nanometers are also advantageous in these blue, violet, orultraviolet light sources that do not employ phosphor.

The invention has been described with reference to the preferredembodiments. Obviously, modifications and alterations will occur toothers upon reading and understanding the preceding detaileddescription. It is intended that the invention be construed as includingall such modifications and alterations insofar as they come within thescope of the appended claims or the equivalents thereof.

1. A light emitting apparatus comprising: one or more light emittingchips emitting light predominantly in a wavelength range between about400 nanometers and about 470 nanometers; and a printed circuit board onwhich the one or more light emitting chips are disposed, the printedcircuit board including: (i) an electrically insulating board, (ii)electrically conductive printed circuitry, and (iii) an electricallyinsulating solder mask having vias through which the one or more lightemitting chips electrically contact the printed circuitry, the soldermask having a reflectance of greater than 60% at least between about 400nanometers and about 470 nanometers, the solder mask including anelectrically insulating binder material and a filler material dispersedin the binder material, the filler material having reflectance greaterthan about 85% at least between about 400 nanometers and about 470nanometers.
 2. The light emitting apparatus as set forth in claim 1,further comprising: a housing inside of which the one or more lightemitting chips and the printed circuit board are disposed, the housingincluding a phosphor arranged to be irradiated by the one or more lightemitting chips and emitting light in a wavelength range predominantlyabove 470 nanometers responsive to the irradiating, the phosphor and theprinted circuit board being relatively arranged such that at least someof the light emitted by the one or more light emitting chipspredominantly in the wavelength range between about 400 nanometers andabout 470 nanometers reflects from the phosphor onto the solder mask ofthe printed circuit board.
 3. The light emitting apparatus as set forthin claim 1, wherein the electrically insulating binder material is aphotostabilized material.
 4. The light emitting apparatus as set forthin claim 1, wherein the binder material is one of a photostabilizedepoxy and a photostabilized polyimide.
 5. The light emitting apparatusas set forth in claim 1, wherein the filler material is one of atitanium oxide and an aluminum oxide.
 6. The light emitting apparatus asset forth in claim 1, wherein the filler material is one of TiO₂ andAl₂O₃.
 7. The light emitting apparatus as set forth in claim 1, whereinthe electrically insulating board comprises: a metal layer; and anelectrically insulating layer disposed on at least one side of the metallayer, the printed circuitry being disposed on the electricallyinsulating layer.
 8. A light emitting apparatus comprising: one or morelight emitting chips emitting light predominantly in a wavelength rangebetween about 400 nanometers and about 470 nanometers; and a printedcircuit board on which the one or more light emitting chips aredisposed, the printed circuit board including: (i) an electricallyinsulating board, (ii) electrically conductive printed circuitry, and(iii) an electrically insulating solder mask comprising a multiple-layerspecular reflector sheet and having vias through which the one or morelight emitting chips electrically contact the printed circuitry, thesolder mask having a reflectance of greater than 60% at least betweenabout 400 nanometers and about 470 nanometers.
 9. The light emittingapparatus as set forth in claim 8, wherein the solder mask has areflectance greater than about 85% at least between about 400 nanometersand about 470 nanometers.
 10. The light emitting apparatus as set forthin claim 8, wherein the solder mask has a reflectance greater than 60%at least between about 400 nanometers and about 740 nanometers.
 11. Thelight emitting apparatus as set forth in claim 8, wherein the soldermask has a reflectance greater than about 85% at least between about 400nanometers and about 740 nanometers.
 12. The light emittingapparatus asset forth in claim 8, wherein the multiple-layer specular reflectorsheet comprises: a stack of reflective dielectric layers formed ofalternating layers of dielectric material having different refractiveindices, different birefringence characteristics, or other dissimilaroptical characteristics.
 13. The light emitting apparatus as set forthin claim 8, further comprising: a phosphor arranged to be irradiated bythe one or more light emitting chips and emitting light in a wavelengthrange predominantly above 470 nanometers responsive to the irradiating,the phosphor and the printed circuit board being relatively arrangedsuch that at least some of the light emitted by the one or more lightemitting chips predominantly in the wavelength range between about 400nanometers and about 470 nanometers reflects from the phosphor onto thesolder mask of the printed circuit board.
 14. The light emittingapparatus as set forth in claim 13, wherein the solder mask has areflectance greater than about 85% at least between about 400 nanometersand an upper wavelength substantially spanning the wavelength range oflight emitted by the phosphor.
 15. A method for fabricating a lightemitting apparatus, the method comprising: providing an electricallyinsulating board with electrically conductive printed circuitry disposedthereon; disposing an electrically insulating solder mask having areflectance of greater than 60% at least between about 400 nanometersand about 470 nanometers on the electrically insulating board bycombining constituents of a photosensitive epoxy with a reflectivefiller material to generate epoxy source material, the reflective fillerhaving a reflectance greater than about 85% at least between 400nanometers and 470 nanometers, disposing the epoxy source material onthe electrically insulating board to define an epoxy solder mask layer,and photolithographically forming the vias accessing the printedcircuitry in the epoxy solder mask layer; and disposing one or morelight emitting chips on the insulating solder mask, the one or morelight emitting chips electrically contacting the printed circuitrythrough the vias in the solder mask, the one or more light emittingchips emitting light emitting light predominantly in a wavelength rangebetween about 400 nanometers and about 470 nanometers.
 16. The method asset forth in claim 15, wherein the providing of an electricallyinsulating board comprises: providing a metal core; disposing aninsulating layer on the metal core; disposing a conductive layer on theinsulating layer; and patterning the conductive layer to define theelectrically conductive printed circuitry.
 17. The method as set forthin claim 15, wherein the disposing of the epoxy source material on theelectrically insulating board includes disposing the epoxy sourcematerial by one of spray coating and curtain coating.